Hinged roof and sidewall forms for a monolithic structure

ABSTRACT

This invention relates to a cast monolithic house and to a apparatus for casting, simultaneously, the roof, end wall and sidewalls thereof at the site. The method involves hinging together roof and sidewall forming portions of a form and lifting such form into place by wheeled carriers. An acme thread with a jam nut mounted on the wheeled carriers, will lift the form into place. While a base slab is poured, a curb-approximately 3 inch X 3 inch is cast above the floor to act as a stop for the interior forming section and to control the thickness of the wall, as well as acting as a seal.

Unite tates Patent Stickler, Jr.

[541 HINGED ROOF AND SIDEWALL FORMS 1,303,251 5 1919 Brunner 249 19 FOR A MONOLITHIC STRUCTURE 1,626,897 5/1927 Wedberg 249/180 1,927,256 9/1933 Copeland e1 211.... 249/185 Inventor: Charles Stiekler, J t 3,012,291 12/1961 Rice 52/69 Pa. 3,064,392 ll/1962 Avril 249/27 3,161,703 12/1964 Watson 249/19 [73] Asslgnee- Tech "dusmes, 3,490,729 1/1970 Luce et all... 249 39 Molmlon 3,630,479 12 1971 Sullivan 249/19 June 3,693,927 9/1972 Jennings 249/181 PP 371,825 Primary Examiner-Robert D. Baldwin Related U.S. Application Data [63] Continuation-impart of Ser. No. 200,060, Nov. 18,

1971, Pat. No. 3,742,102, which is a I ABSTRACT continuationqmpan f Sen 123,539, March 12 Th1s 1nvent1on relates to a cast monol1th1c house and 1971, abandoned. to a apparatus for casting, simultaneously, the roof, end wall and sidewalls thereof at the site. The method [52] US. Cl 425/62, 249/27, 249/185 inv l hinging together roof and sidewall forming [51] Int. Cl E04g 11/02 p ions f a form and lifting uch form into place by [58] Field of Search 425/62; 264/31, wheel d carriers. An acme thread with a jam nut 249/19, 23-24, 26-29, 31, 39, mounted on the wheeled carriers, will lift the form 161, l l7l, -182, into place. While a base slab is poured, a curb- 52/69 approximately 3 inch X 3 inch is cast above the floor to act as a stop for the interior forming section and to [56] References Cited control the thickness of the wall, as well as acting as a UNITED STATES PATENTS seal.

858,924 7/1907 Turner 249/28 8 Claims, 5 Drawing Figures 1,273,244 7/1918 Loxterman 249/182 22 23 1 a t 1., IO D t 1 I a v I 1 t o l I 2 l a I 15 l 2 9 9 '8 X 1 l a 1 1g 1 g 6 9 X 19 l 1 Z .25

l g 7 l 1l= 9 L u 7 8 5 9 A .1- I: f-,.- l 4- Q, 2-*.-: a 'z-; :(.'-A J 3 PATENTEDnuvmsm 3' sumeora HINGED ROOF AND SIDEWALL FORMS FOR A MONOLITHIC STRUCTURE This invention is a continuation-in-part of my application Ser. No. 200,060, filed Nov. I8, 197], now Pat. No. 3,742,102 which was a continuation-in-part of my application Ser. No. 123,539 filed March 12, l97l,

now abandoned, and relates to casting of a concrete house, and, more particularly, to the casting simultaneously, of the roof, two sidewalls and an end wall to rapidly cast a monolithic concrete house unit at the site at minimum cost.

In the past, attempts to reduce the cost of fabricating inexpensive homes have not met with success since it has been necessary to prefabricate partitions and outer wall portions in factories and then crate and ship them to the site for assembly. Such shipment and laborious effort at the site for assembling the prefabricated wall portions have added considerably to the overall cost as well as to the time for construction. Methods for permanently joining such wall portions have not proved satisfactory.

An object of the present invention is to provide novel improvements in a monolithic house construction and apparatus for casting thereof at the site, which will overcome all the abovementioned disadvantages of prior constructions and methods.

A more specific object of the invention is to provide a novel and improved apparatus for including the use of vehicles with flat beds for erecting interior forms to a position for simultaneously casting the roof, two sidewalls and an end wall, and for thereafter withdrawing and removing the forms by the aid of said vehicles so as to easily, quickly and inexpensively cast the entire house at the site without the need of prefabricated outer wall portions.

Another object of the invention is to cast a curb above the floor to act as a stop forthe interior forming section and to control the thickness of the wall, as well as serving as a seal.

Still another object of the invention is to cast a monolithic two story house by employing'the basic principles of the aforesaid method.

Other objects and advantages will become more apparent from a study of the following description, taken with'the accompanying drawings wherein:

FIG. 1 is a top perspective view of a form system for casting a monolithic concrete house in accordance with the principles of the present invention;

FIG. 2 is a fragmentary, vertical, cross-sectional view of FIG. 1 showing one form of roof when casting smaller homes and showing the forms in erected positron;

FIG. 3 is a view similar to FIG. 2 showing a modified mod and showing the form in withdrawn position; and,

FIG. 4 is a vertical, cross-sectional view of a two story monolithic building cast in accordance with the present invention, while FIG. 5 shows the method of erection.

Referring more particularly to FIG. 2 of the drawing, numeral 1 generally denotes a monolithic cementitious building cast in accordance with the present invention and supported on a concrete footer 2.

The prepoured concrete floor slab 3 is prepared for the reception of the casting equipment. The floor slab 3 is'designed and constructed to be adequate for use both as the floor of the house and as the base pad capable of supporting and positioning all the related forming equipment.

The floor slab 3 is constructed of proper concrete and reinforcing steel and is placed as previous to all other construction as deemed necessary and to attain the adequate curing of the concrete required to be assured of proper strength.

The concrete for the floor slab 3 and curb 5 is poured simultaneously to form an integral unit. Curb 5 is approximately 3 inches square above the floor 3, which curb serves as a stop for the interior forming section 14 and which controls the thickness of the sidewall-also, it acts as a seal, therefore eliminating the sill angle formerly used at the bottom of the wall form.

Two interior form carriers 6 are rolled into position on the floor slab, end to end, alongside each of the sidewalls. In some cases, only a single, long carrier may be sufficient for each side, depending upon the length of the building.

The interior form carrier 14 is the main section of the casting machine. When positioned properly, it is capable of forming one quadrant of the interior walls and roof of the house. The carrier 6 is equipped with solid tired wheels 7 (or metal wheels) that may swivel. Carrier 6 has a base frame 8 and at least four posts 9 having threaded to their top ends threaded posts 10 supporting at an angle, frame 11 adapted to support the interior form for the roof. A 1% inches diameter Acme thread is used with a jam nut or a pin to ffix the location, once it has been established, in the initial setup. Turning of the nuts relative to posts 10 mounted on the carrier frame elevates the carriers to the proper height. All sections are hinged at all points necessary to both to set the forms in pouring position and also to enable the forms-to be stripped and have adequate clearance to allow the sections to be removed from the The form carriers in the rear quadrants will include the form for the rear wall and, the form carrier in the front quadrants will include the form for the gable of the open end of the structure. The roof is formed by using roof forming planks which will remain as an integral part of the structure. These planks are supported by a system of gridwork 11, which is on the top section of the interior form carriers, (see FIG. 1) and serve as the roof insulating material.

The form carrier wheels 7 are merely the means to position the casting machine in its proper position on the floor slab 3. They could be straight axles (not shown) or swivel types and are designed for maximum efficiency and best possible weight distribution.

The form carriers are raised to the proper height by screwing the nuts relative to threaded posts 10 or by using built-in screw jacks or turnbuckles (not shown).

By extending the wall form positioning linkage 15 the form 14 to any position necessary to pour and remove the section with adequate clearance.

By swinging the roof forming grids ll, 12, hinged at 13, into position and fastening them to temporary form support columns (not shown), the interior form set-up is completed. The hinges 13 are placed at all points on the forming system where it is necessary to fold" the sections to be able to position all sections properly and to be able to remove the system from thestructure. They are designed to be able to support the necessary weight requirements and are placed to assure that they will remain clean and maintenance free.

The temporary form support columns is a series of temporary shores, either wood, pipe or structural members under the apex of the building that support the roof forming system, for the pouring operation. They support beam 26 to which the extremities of form 12 are temporarily connected by angles or the like.

After the concrete is sufficiently cured, the forming grids are detached from the columns and beam 26, together with the rest of the forming system, is removed. The shape of the roof eaves 22 in FIG. 2 or 22' in FIG. 3 is determined by the adjustment of turnbuckle and the angle to which forming member 21 is positioned. FIG. 2 shows an upward slope to eaves 22 for forming a gutter or channel with the remainder of the roof structure. FIG. 3 however, shows the top surface of the cementitious roof as extending in the same plane without a gutter.

The outer forms 16 are adjustably positioned by turnbuckles 17 having adjusting means 18 and having their extremities anchored to the ground as shown. Of course, after curing of the sidewalls is completed the outer form 16 and turnbuckles 17 are removed as well as turnbuckles 19 and form 21 for supporting the underside of eaves 22 or 22.

As shown in FIGS. 2 and 3, before the concrete is poured blockouts are formed for defining windows, electrical conduits, etc.. Therefore, after curing and after the blockouts or molding elements are removed, window cavities remain as shown in FIGS. 2 and 3 for receiving window frames (or door frames etc.).

As shown more clearly in FIG. 1 during the concrete pouring process, concrete is poured on planks supported by grid 11, for example, by means of trucks having rotating drums for mixing the concrete and outlets extending through a very long, upwardly inclined conduit, simulating a boom, the discharge end of which may be moved by the workmen to different positions between the sidewall and endwall forming forms and tamped as well as vibrated by vibrators (not shown) to eliminate voids. Simultaneously concrete is poured onto the planks (not shown) supported by grids 11 and 12, above which planks metal reinforcing is strung. Similarly metal reinforcing may be inserted between the sidewall and endwall forming forms. When the pouring is substantially completed the roof is screeded by boards or the like, using the outer edges of the roof form as guides, to form a monolithic structure comprising the roof, sidewalls and one end wall.

In some instances, the end wall may be poured last, particularly if two units are placed end-to-end, each having the structure shown in FIG. 1, except for the end wall which occurs only in the unit located at the end of the house.

While the two halves of the end wall forms 32 may be butted together, it is preferable for such forms to overlap as shown at 34, 35 and 36 so as to compensate for any errors in measurement.

At the corners of the building, adjacent form parts 33, filler pieces may be placed to change the thickness of the concrete wall. For example, if a 5 inch wall were required, instead ofa 7 inch wall as otherwise provided by the form, a 2 inch filler piece would be inserted in each joint.

FIG. 4 shows a modification of the building as being a two story building, instead of a one story building, the shell of which is formed in exactly the same manner indicated in FIGS. 1, 2 and 3. However, the sidewalls 40 are formed with substantially central, inwardly, facing grooves 41 into which there is subsequently formed a floor or deck 42 which is cast by inserting a plurality of pans 43, side by side, and pouring of the concrete therein. Each of the pans has sidewalls extending above the height of the floor 42.

The pans 43 are supported by shores and lumber 44. After the pour, the pans 43 are removed and the shores and lumber 44 stay in place until the concrete has cured adequately.

The large concrete area 42a in the center of the floor or deck is a concrete beam cast with the deck and serves the same function as any ordinary beam in the structure.

FIG. 5 shows how the carrier is modified for forming a two story building. The modification includes the provision of an upper extension 45 which is stacked onto stationary U-shaped supports 46. The remainder of the structure is the same as that previously described. A modification would be to have extensions 45 telescope into the side posts of the carrier so as to bring the overall height down to about 8 ft. for ease of transportation of the carrier assembly.

Thus it will be seen that I have provided a strong and durable cast concrete house having long life and I have also provided an efficient method for eating integrally and simultaneously the sidewalls, end wall and roof of such house, to quickly form a monolithic structure at the site without the necessity of transporting prefabricated sections; furthermore, I have provided a unique and very fast method for transporting, erecting and withdrawing the forms to enable casting of a unitary structure which is considerably stronger than structures heretofore constructed, and which is devoid of joints between the sidewalls, end wall and roof and which structure can be erected in an amazingly short time at amazingly low cost.

While I have illustrated and described a single specific embodiment of my invention, it will be understood, that this is by way of illustration only and that various changes and modifications may be contemplated in the specification and within the scope of the following claims.

I claim:

1. A form assembly for simultaneously casting a pair of roof and sidewall portions of a building to form a monolithic structure, comprising apair of side by side wheeled, rectangular carriers, each carrier having two corner posts located at the corners farthest from the other carrier and two corner posts of greater height located at opposite corners of the carrier, jacking means connected to each of said corner posts, a pair of interior forms, each supported by one of said carriers and including a roof forming portion supported on the corner posts of the corresponding carrier in slanted position to enable lifting and lowering of said roof forming portion and a sidewall forming portion pivotally connected to one end of said roof forming portion suspended in substantially vertical position, each of said roof forming portions having a pivotal extension means whose end is located substantially at the apex formed by the side by side roof forming portions, means for bridging and supporting said ends of said pivotal extens iQn @a ns in confronting relationship, a second jacking means extending laterally frointhe lower side portion of each carrier and pivotally connected to the adjacent interior sidewall forming portion to enable pivotal movement of said sidewall forming portion away from a vertical position after casting of the sidewall, and a pair of vertical exterior forms spaced from said sidewall forming portions.

2. A form assembly as recited in claim 1 wherein each of said vertical exterior forms comprises a top pivotal section and mechanical means connected therebetween to enable pivoting of said top pivotal section to form selective eave angles relative to the roof forming portions.

3. A form assembly as recited in claim 1 together with a concrete floor on which said carriers are supported, and a concrete stop element integrally cast with said floor and extending about the perimeter of the floor in spaced relationship with said vertical exterior forms to limit pivotal outward movement of said interior sidewall forming portions to confine them to a vertical position.

4. A form assembly as recited in claim 1 together with a horizontally extending frame element located underneath and parallel to the apex formed by the side by side roof forming portions and against which said ends of said extension means of the roof forming portions are abutted before casting.

5. A form assembly as recited in claim 2 wherein said interior roof forming portions are each in the form of a grid surrounded by upstanding end wall portions, whereby the roof may be cast and screeded without the necessity of exterior roof forming form portions.

6. A form assembly as recited in claim 2 wherein said building is a two story building and wherein each sidewall forming portion includes means for forming horizontally extending, spaced, confronting grooves formed substantially centrally between the top and bottom of the cast sidewalls, said grooves adapted to support means for casting a concrete floor between said grooves.

7. A form assembly as recited in claim 2 together with an interior end wall forming portion carried by the corresponding carrier, and an exterior end wall forming portion spaced therefrom whereby an end wall will also be simultaneously cast to form a monolithic structure including sidewalls, roof and an end wall.

-8. A form assembly as recited in claim 1 wherein said wheeled carriers include swivelly mounted wheels. 

1. A form assembly for simultaneously casting a pair of roof and sidewall portions of a building to form a monolithic structure, comprising a pair of side by side wheeled, rectangular carriers, each carrier having two corner posts located at the corners farthest from the other carrier and two corner posts of greater height located at opposite corners of the carrier, jacking means connected to each of said corner posts, a pair of interior forms, each supported by one of said carriers and including a roof forming portion supported on the corner posts of the corresponding carrier in slanted position to enable lifting and lowering of said roof forming portion and a sidewall forming portion pivotally connected to one end of said roof forming portion suspended in substantially vertical position, each of said roof forming portions having a pivotal extension means whose end is located substantially at the apex formed by the side by side roof forming portions, means for bridging and supporting said ends of said pivotal extension means is confronting relationship, a second jacking means extending laterally from the lower side portion of each carrier and pivotally connected to the adjacent interior sidewall forming portion to enable pivotal movement of said sidewall forming portion away from a vertical position after casting of the sidewall, and a pair of vertical exterior forms spaced from said sidewall forming portions.
 2. A form assembly as recited in claim 1 wherein each of said vertical exterior forms comprises a top pivotal section and mechanical means connected therebetween to enable pivoting of said top pivotal section to form selective eave angles relative to the roof forming portions.
 3. A form assembly as recited in claim 1 together with a concrete floor on which said carriers are supported, and a concrete stop element integrally cast with said floor and extending about the perimeter of the floor in spaced relationship with said vertical exterior forms to limit pivotal outward movement of said interior sidewall forming portions to confine them to a vertical position.
 4. A form assembly as recited in claim 1 together with a horizontally extending frame element located underneath and parallel to the apex formed by the side by side roof forming portions and against which said ends of said extension means of the roof forming portions are abutted before casting.
 5. A form assembly as recited in claim 2 wherein said interior roof forming portions are each in the form of a grid surrounded by upstanding end wall portions, whereby the roof may be cast and screeded without the necessity of exterior roof forming form portions.
 6. A form assembly as recited in claim 2 wherein said building is a two story building and wherein each sidewall forming portion includes means for forming horizontally extending, spaced, confronting grooves formed substantially centrally between the top and bottom of the cast sidewalls, said grooves adapted to support means for casting a concrete floor between said grooves.
 7. A form assembly as recited in claim 2 together with an interior end wall forming portion carried by the corresponding carrier, and an exterior end wall forming portion spaced therefrom whereby an end wall will also be simultaneously cast to form a monolithic structure including sidewalls, roof and an end wall.
 8. A form assembly as recited in claim 1 wherein said wheeled carriers include swivelly mounted wheels. 